U.S. patent application number 14/870528 was filed with the patent office on 2016-04-07 for apparatus to produce 3d curved flocked articles.
The applicant listed for this patent is TamiCare Ltd.. Invention is credited to Ehud GILOH.
Application Number | 20160096190 14/870528 |
Document ID | / |
Family ID | 54708073 |
Filed Date | 2016-04-07 |
United States Patent
Application |
20160096190 |
Kind Code |
A1 |
GILOH; Ehud |
April 7, 2016 |
Apparatus to produce 3D curved flocked articles
Abstract
An apparatus for flocking a curved article is disclosed. The
apparatus includes a flocking machine having a curved mesh with a
plurality of sectors, the curved mesh being constructed to conform
to the curve of a curved object to be flocked. The curved object
also includes a plurality of sectors, and is placed at a distance
from the curved mesh such that a constant gap is provided between
each sector on the curved object and the corresponding sector of
the curved mesh.
Inventors: |
GILOH; Ehud; (Heywood,
GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
TamiCare Ltd. |
Heywood |
|
GB |
|
|
Family ID: |
54708073 |
Appl. No.: |
14/870528 |
Filed: |
September 30, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62058192 |
Oct 1, 2014 |
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Current U.S.
Class: |
118/308 |
Current CPC
Class: |
B05C 19/008 20130101;
B05C 19/001 20130101; B05C 19/004 20130101; B05B 7/145 20130101;
B05C 19/002 20130101; B05B 5/081 20130101; D04H 11/00 20130101 |
International
Class: |
B05C 19/00 20060101
B05C019/00 |
Claims
1. An apparatus for flocking curved article, said apparatus
comprising: a flocking machine, said flocking machine comprising a
curved mesh having a plurality of sectors; said curved mesh
constructed to conform to a curved object to be flocked, wherein
the curved object includes a plurality of sectors, and wherein the
curved object is placed at a distance from the mesh such that a
constant gap is provided between each sector on the curved object
and the corresponding sector of the curved mesh.
2. The apparatus of claim 1 wherein the mesh is pre-made to match
the curve of the object to be flocked before being installed onto
the flocking machine.
3. The apparatus of claim 1 further comprising a brush, wherein
said brush shape conforms, at least partially, to the shape of the
flocking machine curved mesh.
4. The apparatus of claim 3 wherein said brush moves, vibrates, or
rotates on top of or adjacent to the mesh, causing the fibers to
move through the mesh.
5. The apparatus of claim 1, wherein the mesh itself rotates or
vibrates, causing the fibres to move through said mesh.
6. The apparatus of claim 1 further comprising a pneumatic device
utilizing pressurized air or gas to assist pushing the fibers
towards the object to be flocked.
7. The apparatus according to claim 1 wherein the curved object is
a part of or is placed on a conveying system.
8. The apparatus according to claim 1 wherein the curved mesh is a
part of a moving carousel.
9. The apparatus according to claim 8 wherein the moving carousel
comprises a plurality of curved meshes.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional
Application Ser. No. 62/058,192, filed Oct. 1, 2014, the entire
contents of which are incorporated herein by reference for all
purposes.
BACKGROUND
[0002] Production of 3D curved flocked articles in an industrial
process introduces a major challenge in overcoming the shortcomings
of the current flocking technology, mainly due to limitations of
the flocking machines structure and technique.
[0003] A common flocking machine comprises a container equipped
with a mesh, the mesh facing the object to be flocked, which is
usually below the mesh. A brush or another means for discharging
fibres via the mesh is also provided. The process comprises a step
of presenting static or moving object/s below the mesh, for the
flocking session.
[0004] The existing technologies and equipment suffer drawbacks
related to uniformity and quality of coverage, as well as
limitations related to the speed of flocking process. Moreover, the
existing technology does not allow sufficient flock coating
uniformity of curved objects when the process is carried out in
mass production system or when the products to be flocked are
moving on a conveyor belt in an industrial manufacturing line.
[0005] It is also difficult to create uniform flock coverage on
curved objects, even when an electrostatic flocking is engaged, as
the electrostatically charged fibres are attracted to the nearest
points of the convex object/s to be flocked. Additionally, the
`Faraday cage` effect makes it hard to flock concave objects.
Therefore, pneumatic flocking equipment which employs a stream of
pressurized air to blow the fibres into the concaved area is
usually used.
[0006] The pneumatic system may require moving the pneumatic
flocking application head along the flocked curved object. The need
for moving the flocking machine above the object makes the process
very slow and complicated, yet not necessarily providing the
desired uniformity.
[0007] Therefore it is desired to provide a simple and reliable
flocking system for 3D curved surfaces, particularly when the
flocking process is employed in mass production manufacturing
lines, where repeatability and consistency are crucial.
SUMMARY OF THE INVENTION
[0008] An apparatus is provided for producing a uniformed flocked
coating on 3D or curved surfaces or objects is disclosed herein.
The system relates to a production process wherein a liquid or any
other suitable sprayable material may be applied on a curved
surface, such as curved or 3D mold, curved or 3D mold mounted on a
conveyor belt, curved conveyor belt or any other curved object.
[0009] Such a conveyor belt or system may be mounted adjacent to
the flocking unit, as an example, or can be mounted below the
flocking unit at such distance so that a gap suitable for
performing the flocking process is provided, as known to a skilled
person in the flocking art.
[0010] Alternatively, the object may be a semi-finished product,
brought to the process from different production system, requires
an additional production step of flock coating.
[0011] The invention introduces a unique flocking system which
features a 3D curved design of the mesh component of the flocking
unit, where the 3D curved design complements or correlates with the
object to be flocked, so that every sector on the curved object (to
be covered with flocked fibers) is situated at an approximately
similar distance from a conforming sector on the flocking machine
mesh.
[0012] An apparatus configured for carrying out the improved
flocking method is also disclosed herein. The apparatus may be a
part of a production line, a part of a small scale non-industrial
apparatus or a part of any other production apparatus that can
produce flocked products. The disclosed apparatus may be used also
as a stand-alone apparatus.
[0013] The apparatus comprises a flocking device equipped with a
curved mesh, wherein the shape of the curved mesh substantially
complements or conforms to the shape of the curved object or
surface to be flocked, while maintaining a constant, uniform gap
(distance) between the object to be flocked and the flocking
apparatus curved mesh, so that every given point or zone on the
curved object to be flocked is situated at an approximately similar
distance from the corresponding point on the flocking apparatus
curved mesh. The distance is measured perpendicular to the given
point on the surface of the object to be flocked. The curved mesh
can be pre-made by any suitable means to match the specific shape
of the object to be flocked. For instance, a single piece of steel
mesh can be bent into a curve using a conventional bending machine.
The curved mesh provides even and uniform flocking, as the fibers
along the entire outline of the flocking apparatus mesh are applied
from an equal distance, so that fibers speed and distribution is
uniform and even, this applies to any flocking technique,
electrostatic, non-electrostatic, pneumatic, or any other flocking
method.
DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 illustrates one embodiment of a flocking machine for
flocking a curved object of the present application.
[0015] FIG. 2 illustrates another embodiment of a flocking machine
for flocking a curved object of the present application including a
brush.
[0016] FIG. 3 illustrates a carousel based flocking machine with a
number of curved mesh components and a corresponding conveyor
belt.
DETAILED DESCRIPTION OF THE INVENTION
[0017] In this application, the terms "object", "mould" (mold),
"former", "workpiece" and "surface" are interchangeable.
[0018] In this application, the term "flocking" refers to coating a
surface with loose fibers, such as but not limited to: cotton,
viscose, polyamide, polyester, wool, silk, metal, plastic, glass,
rubber, SAF, any other suitable fibers. Usually such fibers are
approximately 0.2 to 20 mm long.
[0019] An example process for producing a 3D curved flocked article
may comprise the following steps: (a) providing a curved object;
(b) applying a material to the curved object; the material may be
wet or sticky. As an example, the material can be sprayed or
brushed. (c) flocking the curved object using a flocking machine
(100), comprising a curved mesh (101); the curved mesh (101)
outline conforming to the outline of the curved object (10) or
surface to be flocked, while maintaining a constant gap (102)
between the object to be flocked and the flocking apparatus curved
mesh (101), so that every given point or zone of the curved object
(10) or surface to be flocked, is situated at an approximately
similar distance from the corresponding point on the flocking
apparatus curved mesh (101). The curved object 10 is placed and
held at a distance from the curved mesh 101 to create the gap
102.
[0020] The curved object may be, or may consist of, without
limitation, a curved conveyor system, a series of curved objects or
series of curved objects placed on a moving conveyor system, a
finished product/s, a semi-finished product/s or product/s in
process. The curved object/s can include convex or concave areas
and can be used for manufacturing of any desired product/s such as
but not limited to garments, lingerie, panties, bras, shoes,
medical bandages and dressing, decorations, clothing, carpets,
pads, boxes or any other curved objects.
[0021] In at least one step of material application, the material
application may include applying any suitable material such as
liquid or other sprayable material on at least a part of the
object. Such materials may include, but is not limited to gels,
natural, artificial or synthetic polymer in the form of a liquid,
solution or suspension, foam, release agent, hot melt, adhesive or
powder, such material can be applied by any suitable application
device, such as but not limited to: spray gun, electrostatic spray
gun, brush, pad, or any other suitable device.
[0022] As shown in FIG. 1, the step of flocking includes the use of
a flocking machine (100), comprising a curved mesh (101) having a
plurality of sectors or zones, the curved (101) mesh outline being
constructed to substantially conform to the shape or outline of the
curved object (10) or surface to be flocked. The curved object
includes a plurality of sectors or zones, and each sector has a
constant gap (102) between the object to be flocked and the
flocking apparatus curved mesh (101), so that every given sector,
point or zone of the curved object (10) or surface to be flocked is
situated at a substantially similar distance from the corresponding
point on the flocking apparatus curved mesh (101).
[0023] In one embodiment, the flocking machine comprises a curved
brush, (103) which conforms to the shape of the mesh (101). The
curved brush is positioned adjacent to the mesh, the brush can
move, vibrate, or rotate, by any suitable moving device, such as
but not limited to: a motor, a pneumatic piston, eccentric turbine,
or any other suitable device, on top of the mesh, so that the
flocked fibers (20) are pushed by the brush movement, and therefore
transferred through the mesh (101).
[0024] In another embodiment, the mesh (101) itself rotates or
vibrates, causing the fibres (20) to move through said mesh. The
mesh can be moved or driven by any suitable moving device, such as
but not limited to: a motor, a pneumatic piston, eccentric turbine,
or any other suitable device. The moving device may be connected to
the mesh by any suitable means, such as by a shaft and screw, for
example.
[0025] In yet another embodiment, the mesh moves next to or above
the series of objects, in same speed of the objects, maintaining a
uniform, even gap between the mesh and the objects.
[0026] The core of this invention is the flocking machine curved
mesh which conforms to the shape of the curved object/s (to be
coated with flocked fibers) and follow its outline/s, keeping a
uniform, even, gap or distance from the object to be flocked
outline and the mesh outline. Any mesh arrangement, configuration
or embodiment may be used in the machine of the present
application, such as but not limited to a closed loop curved mesh
carousel (104), a plurality of moving curved meshes or any other
suitable arrangement. The moving carousel 104 may comprise a
plurality of curved meshes.
[0027] In yet another embodiment, a pneumatic flocking system, or
pneumatic assisted flocking system utilizing pressurized air or gas
can be used to assist or perform pushing the fibers through the
mesh (101). Pressurized air can be provided by any suitable means,
such as but not limited to: a compressor, a turbine, fan or by any
other suitable device, as known in the flocking art.
[0028] Representative examples of curved articles to be
manufactured using the disclosed apparatus include, without
limitation, any product such as but not limited to garments,
including lingerie, panties, bras, shoes, medical bandages and
dressing, decorations, clothing, carpets, pads, boxes or any other
suitable curved objects.
[0029] The apparatus comprising a flocking machine (100), said
flock machine comprising a curved mesh (101), the curved mesh
conforming to a specific curved object (to be flocked) (10), so
that every given zone on the curved object (10) is situated at a
proximate similar distance (102) from a corresponding zone on the
flocking machine mesh (101).
[0030] The flocking machine may comprise an optional curved brush,
(103) wherein the flocked fibres (20) are transferred through the
mesh (101), by the curved brush (103), which has a shape conforming
to at least part of the mesh curved shape, the brush moves vibrate
or rotates adjacent to the mesh (101), therefore pushing the fibers
(20) through the mesh (101).
[0031] The mesh (101) may rotates or vibrate, relatively to the
mesh, causing the fibres (20) to move through the mesh.
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